EP3115678B1 - Procédé de production d'un phare de véhicule et phare de véhicule associé - Google Patents

Procédé de production d'un phare de véhicule et phare de véhicule associé Download PDF

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Publication number
EP3115678B1
EP3115678B1 EP16172044.6A EP16172044A EP3115678B1 EP 3115678 B1 EP3115678 B1 EP 3115678B1 EP 16172044 A EP16172044 A EP 16172044A EP 3115678 B1 EP3115678 B1 EP 3115678B1
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EP
European Patent Office
Prior art keywords
lenticular body
light
redirection
welding
side wall
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP16172044.6A
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German (de)
English (en)
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EP3115678A1 (fr
Inventor
Domenico Ferigo
Sara Paroni
Davide Sammito
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Marelli Automotive Lighting Italy SpA
Original Assignee
Marelli Automotive Lighting Italy SpA
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Publication date
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Priority to PL16172044T priority Critical patent/PL3115678T3/pl
Publication of EP3115678A1 publication Critical patent/EP3115678A1/fr
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Publication of EP3115678B1 publication Critical patent/EP3115678B1/fr
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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21K—NON-ELECTRIC LIGHT SOURCES USING LUMINESCENCE; LIGHT SOURCES USING ELECTROCHEMILUMINESCENCE; LIGHT SOURCES USING CHARGES OF COMBUSTIBLE MATERIAL; LIGHT SOURCES USING SEMICONDUCTOR DEVICES AS LIGHT-GENERATING ELEMENTS; LIGHT SOURCES NOT OTHERWISE PROVIDED FOR
    • F21K9/00—Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
    • F21K9/90—Methods of manufacture
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/20—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by refractors, transparent cover plates, light guides or filters
    • F21S41/29—Attachment thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1635—Laser beams characterised by the way of heating the interface at least passing through one of the parts to be joined, i.e. laser transmission welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1664—Laser beams characterised by the way of heating the interface making use of several radiators
    • B29C65/1667—Laser beams characterised by the way of heating the interface making use of several radiators at the same time, i.e. simultaneous laser welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1687—Laser beams making use of light guides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1687—Laser beams making use of light guides
    • B29C65/169—Laser beams making use of light guides being a part of the joined article
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/301—Three-dimensional joints, i.e. the joined area being substantially non-flat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
    • B29C66/542—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles joining hollow covers or hollow bottoms to open ends of container bodies
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V17/00—Fastening of component parts of lighting devices, e.g. shades, globes, refractors, reflectors, filters, screens, grids or protective cages
    • F21V17/10—Fastening of component parts of lighting devices, e.g. shades, globes, refractors, reflectors, filters, screens, grids or protective cages characterised by specific fastening means or way of fastening
    • F21V17/101—Fastening of component parts of lighting devices, e.g. shades, globes, refractors, reflectors, filters, screens, grids or protective cages characterised by specific fastening means or way of fastening permanently, e.g. welding, gluing or riveting
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V3/00—Globes; Bowls; Cover glasses
    • F21V3/04—Globes; Bowls; Cover glasses characterised by materials, surface treatments or coatings
    • F21V3/06—Globes; Bowls; Cover glasses characterised by materials, surface treatments or coatings characterised by the material
    • F21V3/062—Globes; Bowls; Cover glasses characterised by materials, surface treatments or coatings characterised by the material the material being plastics
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V5/00—Refractors for light sources
    • F21V5/04—Refractors for light sources of lens shape
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/16—Laser beams
    • B29C65/1629—Laser beams characterised by the way of heating the interface
    • B29C65/1664—Laser beams characterised by the way of heating the interface making use of several radiators
    • B29C65/1667—Laser beams characterised by the way of heating the interface making use of several radiators at the same time, i.e. simultaneous laser welding
    • B29C65/167—Laser beams characterised by the way of heating the interface making use of several radiators at the same time, i.e. simultaneous laser welding using laser diodes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/747—Lightning equipment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60Y—INDEXING SCHEME RELATING TO ASPECTS CROSS-CUTTING VEHICLE TECHNOLOGY
    • B60Y2410/00—Constructional features of vehicle sub-units
    • B60Y2410/12—Production or manufacturing of vehicle parts
    • B60Y2410/124—Welded parts
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S43/00—Signalling devices specially adapted for vehicle exteriors, e.g. brake lamps, direction indicator lights or reversing lights
    • F21S43/20—Signalling devices specially adapted for vehicle exteriors, e.g. brake lamps, direction indicator lights or reversing lights characterised by refractors, transparent cover plates, light guides or filters
    • F21S43/27—Attachment thereof
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21W—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO USES OR APPLICATIONS OF LIGHTING DEVICES OR SYSTEMS
    • F21W2107/00—Use or application of lighting devices on or in particular types of vehicles
    • F21W2107/10—Use or application of lighting devices on or in particular types of vehicles for land vehicles

Definitions

  • This invention relates to a method of making a vehicle light and to a related vehicle light obtained with said method.
  • vehicle light means both a rear vehicle tail light or a front vehicle headlight, the latter also called projector, or headlamp.
  • a vehicle light is a lighting and/or signalling device of a vehicle comprising at least one external light of the vehicle having a function of lighting and/or signalling towards the outside of a vehicle such as, for example, a position light, a turn signal light, a brake light, a rear fog light, a back-up light, a low beam, a high beam and the like.
  • the vehicle light in its most simple abstraction, comprises a container body, a lenticular body and at least one light source.
  • the lenticular body is placed so as to close a mouth of the container body so as to form a housing chamber. Inside the housing chamber is arranged the light source, which can be directed so as to emit light towards the lenticular body, when electrically powered.
  • the method of making a vehicle light once the various components are assembled, must provide for the fixing and sealing of the lenticular body on the container body.
  • the lenticular bodies and the container bodies of vehicle lights are made of polymeric materials and comprise very complex geometries with curved or rectilinear coupling surfaces having inclinations that are also highly variable along the entire mutual coupling perimeter.
  • a low wall or welding interface as a function of the geometry of the light to be welded, can have sudden changes of inclination with respect to the upper outer surface of the lenticular body, on which a laser beam is incident.
  • the purpose of this invention is therefore to weld vehicle lights using a laser welding technique by overcoming the technical drawbacks linked to the specificity of vehicle lights that today make such a welding technique inconvenient and expensive.
  • This purpose is achieved through a method of making a vehicle light according to claim 12 and by means of a vehicle light according to claim 1.
  • reference number 4 indicates a vehicle light in its entirety, to which the discussion that follows will refer without, for this reason, losing generality.
  • vehicle light means both a rear vehicle tail light or a front vehicle headlight, the latter also called projector, or headlamp.
  • a vehicle light comprises at least one external light of the vehicle having a function of lighting and/or signalling, such as, for example, a position light, which can be a front, rear or side position light, a turn signal light, a brake light, a rear fog light, a low beam, a high beam and the like.
  • a position light which can be a front, rear or side position light, a turn signal light, a brake light, a rear fog light, a low beam, a high beam and the like.
  • the vehicle light 4 comprises a container body 8, usually made of polymeric material, which typically allows fixing the vehicle light 4 to the related vehicle.
  • the container body 8 can have any shape and size, as well as positioning: for example, the container body may not be directly associated to the bodywork or to other hardware of the associable vehicle.
  • the container body 8 delimits a containment seat 12 that houses at least one light source (not shown), electrically connected by to electrical connection means for powering it, and suitable to emit a light beam to be propagated outside of the vehicle light.
  • the type of light source used is irrelevant; preferably, the light source 14 is a light emitting diode (LED) light source.
  • the container body 8 is delimited by a first perimetral profile 20.
  • a lenticular body 24 To the container body 8 is associated a lenticular body 24, in its turn delimited by a second perimetral profile 28.
  • the lenticular body 24 is applied to the container body 8 so as to close said containment seat 12, which houses at least one light source.
  • the lenticular body 24 can be outside the vehicle light 4, so as to define at least one outer wall of the vehicle light directly exposed to the atmosphere.
  • the lenticular body 24 closes the containment seat 12 and is suitable to transmit towards the outside of the vehicle light 4 the light beam produced by the light source 14.
  • the lenticular body 24 is made with material at least partially transparent, semi-transparent or translucent, also being able to include one or more opaque portions, so as, in any case, to allow the at least partial passage of the light beam produced by the light source.
  • the material of the lenticular body 24 is a resin such as PMMA, PC and the like.
  • the first and second perimetral profile 20,28 of the container body 8 and of the lenticular body 24 are at least partially counter-shaped to each other so as to interface, in an assembly configuration of the vehicle light 4, at a welding interface 32 of an abutment edge 36 of the lenticular body 24.
  • the weld bead is formed at the welding interface 32 and there is the partial interpenetration of the abutment edge 36 and/or of the corresponding first perimetral profile 16.
  • the assembly of the vehicle light 4 comprises the step of associating at least partially with each other the respective first and second perimetral profile 20,28.
  • the method of making the vehicle light according to this invention provides for associating together the lenticular body and the container body, in correspondence of said perimetral profiles 20,28, by means of a laser weld.
  • the laser welding process can be performed with different techniques, for example, with simultaneous laser welding, quasi-simultaneous welding, contour laser welding, mask laser welding, radial laser welding, globe laser welding, etc.
  • At least one laser source is required, which emits a laser ray, light beam or electromagnetic radiation.
  • the laser source comprises a CO2 laser, wherein the laser beam is produced by a gas mixture comprising CO2, or a YAG laser, wherein the laser beam is produced by a solid-state crystal, or a laser diode (LD).
  • a CO2 laser wherein the laser beam is produced by a gas mixture comprising CO2, or a YAG laser, wherein the laser beam is produced by a solid-state crystal, or a laser diode (LD).
  • the welding of the lenticular body 24 on the container body 8 is a laser type welding, wherein the light beam emitted by the laser source is directed towards the perimetral profiles 20,28 so as to reach the first perimetral profile 20 of the container body 8 after passing through the lenticular body 24.
  • the container body 8 serves as an absorbent element in relation to the light beam emitted by the laser source and the lenticular body 24 serves as a transmissive element of the same light beam.
  • the lenticular body 24 is a body made of polymeric material having transmittance values, in the emission spectrum of the laser source, greater than 90%.
  • the lenticular body (24), at said abutment edge 36, comprises means of redirection 40 adapted to receive laser beams emitted by a laser source external to the light 4 and to the containment seat 12, to reflect them satisfying the condition of total internal reflection (TIR) and to direct them towards said welding interface 32.
  • TIR total internal reflection
  • the means of redirection 40 are facing the containment seat 12 so as not to be visible from the outside of the vehicle light 4; the laser beams are emitted by a source external to the vehicle light 4 so as to penetrate through the lenticular body 24 and reach the means of redirection 40 arranged internally in the vehicle light 4, namely its containment seat 12.
  • Said laser beams impact an outer side wall 44 of the lenticular body 24, opposite the containment seat 12 and, after passing through the lenticular body 24, directly or by at least one reflection, impact said redirection means 40.
  • the means of redirection 40 are, in turn, arranged on an inner face 48 of the abutment edge 36, said inner face 48 facing the containment seat 12 and being incident with the welding interface 32.
  • the redirection means 40 are located in the inner side wall 56 of the lenticular body 24.
  • the redirection means 40 are advantageously arranged on the inner side wall 56 of the lenticular body 24; said inner side wall 56 extends to the inner face 48 of the abutment edge 36, which is incident with the welding interface 32.
  • the redirection means 40 can therefore be positioned generally on the inner side wall 56 of the lenticular body 24 and also on the inner face 48 of the abutment edge 36.
  • Redirection means 40 means a portion of lenticular body 24 shaped so as to receive laser beams emitted by the external laser source, to reflect them satisfying the condition of total internal reflection (TIR) and to direct them towards said welding interface 32.
  • TIR total internal reflection
  • the means of redirection 40 extend perimetrally in a continuous manner, along the entire abutment edge 36 of the lenticular body 24, on the inner face 48 of said abutment edge 36.
  • said means of redirection 40 comprise a planar wall 52, having at least one rectilinear profile with respect to a cross-section plane S-S perpendicular to the welding interface 32 and perpendicular to a plane R-R tangent to an inner side wall 56 of the lenticular body 24, opposite said outer side wall 44.
  • planar wall 52 is inclined so as to identify with the welding interface 32 an acute angle, on the side opposite the containment seat 12.
  • the means of redirection 40 have a section defined by a polyline comprising a plurality of linear walls provided with rectilinear profiles, each straight profile identifying with the welding interface 32 an acute angle, on the side opposite the containment seat 12.
  • the redirection means 40 comprise a curvilinear wall 60 having at least one hyperbolic profile 64, with respect to a cross-section plane S-S perpendicular to the welding interface 32 and perpendicular to a plane tangent to an inner side wall 56 of the lenticular body 24, opposite said outer side wall 44, in which a focus F of said hyperbolic profile 64 is positioned in the vicinity of said welding interface 32.
  • the redirection means 40 comprise a curvilinear wall 60 having at least one parabolic profile 68, with respect to a cross-section plane S-S perpendicular to the welding interface 32 and perpendicular to a plane R-R tangent to an inner side wall 56 of the lenticular body 24, opposite said outer side wall 44, in which a focus F of said hyperbolic profile 68 is positioned in the vicinity of said welding interface 32.
  • the redirection means 40 comprise a curvilinear wall 60 having at least one curvilinear profile 72, with respect to a cross-section plane S-S perpendicular to the welding interface 32 and perpendicular to a plane tangent to an inner side wall 56 of the lenticular body 24, opposite said outer side wall 44, said curvilinear profile 72 being shaped in such a way as to identify a hyperbolic profile 76 facing towards the incident laser rays, on the opposite side of the containment seat 12.
  • the abutment edge 36 is positioned in a position recessed with respect to an outer side wall 44 of the lenticular body 24, i.e. on the side of the containment seat 12, in which the outer side wall 44 is opposite the inner side wall 56 of the lenticular body 24 that at least partly defines said containment seat 12.
  • the abutment edge 36 has a width or thickness T reduced with respect to a thickness 80 of the lenticular body 24, in which the thickness 80 of the lenticular body 24 is given by the distance between the outer side wall 44 and the inner side wall 56. This distance is measured perpendicularly to the respective walls 44,56.
  • the reduced thickness T of the abutment edge 36 facilitates the concentration of the laser beams and therefore concentrates the heat energy on the welding interface 32 in order to have an effective local melting of the same with the formation of a weld bead.
  • the means of redirection 40 of the abutment edge 36 are obtained by means of a recess 84 formed on said inner side wall 56 of the lenticular body 24.
  • a recess 84 formed on the inner side wall 56 of the lenticular body 24 is joined to the inner face 48 of the abutment edge 36 so as to create the planar 52 or curvilinear 60 wall of the redirection means 40.
  • the method of making a vehicle light according to this invention comprises the steps of:
  • the light beams emitted by the fibres are shown with the arrows B, so as to also schematically represent the reflections that these beams undergo inside the lenticular body 24 before impacting on the abutment edge 36 and on the welding interface 32.
  • the means of redirection 40 are facing the containment seat 12 so as not to be visible from the outside of the vehicle light 4; the laser beams are emitted by a source external to the vehicle light 4 so as to penetrate through the lenticular body 24 and reach the means of redirection 40 arranged internally in the vehicle light 4, namely its containment seat 12.
  • the step of directing the laser beams on the outer side wall 44 of the lenticular body 24 comprises the step of positioning the optical fibres 88 from a side of the outer side wall 44 of the lenticular body 24 so that the laser beams impact, directly or by at least one reflection, on the means of redirection 40 of the lenticular body 24 and, via the latter, impact the welding interface 32.
  • the optical fibres 88 can be placed in an appropriate way in the space, also according to orientations different from each other, without physically interfering with each other, since the redirection means 40 of the lenticular body 24 allow suitably directing the rays coming from said optical fibres on the welding interface 32.
  • Different orientations means that the optical fibres 88 can be parallel and/or skewed.
  • the laser rays emitted can be either convergent, parallel or skewed with each other.
  • the method of making a vehicle light comprises the step of providing at least one collimator device 92 between the optical fibres 88 and the lenticular body 24, so as to collimate along a predetermined optical axis X-X, the light beams coming from the optical fibres 88 and directing appropriately on the lenticular body 24 the light beams coming from the optical fibres 88, so that said light beams impact, directly or through at least one reflection, the means of redirection 40 facing the container body 8 on the side of the inner side wall 56 of the lenticular body 24.
  • the collimator device 92 comprises a negative light guide 96, i.e. a light guide formed of reflective walls 100 inclined with respect to the optical axis X-X of the optical fibre 88, and in which the optical fibre 104 is positioned in the vicinity of an upper opening 104 of the negative light guide 96 and along the optical axis X-X.
  • a negative light guide 96 i.e. a light guide formed of reflective walls 100 inclined with respect to the optical axis X-X of the optical fibre 88, and in which the optical fibre 104 is positioned in the vicinity of an upper opening 104 of the negative light guide 96 and along the optical axis X-X.
  • the collimator device 92 comprises a positive light guide 108, i.e. a solid body suitable for satisfying the condition of total internal reflection for the at least one portion of incident laser beam, in which the solid body extends from an inlet 112 to an outlet 114, wherein the inlet 112 is facing said optical fibres 88 and the outlet 114 is facing said lenticular body 24, wherein the solid body is composed of a material transparent to the emission wavelength of the laser beam.
  • a positive light guide 108 i.e. a solid body suitable for satisfying the condition of total internal reflection for the at least one portion of incident laser beam, in which the solid body extends from an inlet 112 to an outlet 114, wherein the inlet 112 is facing said optical fibres 88 and the outlet 114 is facing said lenticular body 24, wherein the solid body is composed of a material transparent to the emission wavelength of the laser beam.
  • the laser welding techniques for the implementation method according to this invention can be of various types; for example, the laser welding step takes place by means of one or more optical fibres 88 that emit respective light radiations simultaneously to each other on different predetermined portions of said perimetral profiles 20,28, according to a "simultaneous" welding technique.
  • this invention allows overcoming the drawbacks presented in the prior art.
  • the light beam that strikes the interface is thus adequate to obtain a welding joint with excellent mechanical qualities, without wasting light power.
  • the laser welding step performed with any technique, for example, "contour” or “simultaneous", is fast and reliable, allowing a further reduction of assembly costs with equal joint quality with respect to the known techniques.
  • the light beam is at least partially absorbed by the lenticular body and therefore, in order to locally melt the container body (absorbent) in correspondence of the interface surface, it is necessary to send a high-power light beam. In this way, consumption would be increased, on the one hand, and there is a risk of unwanted melting or softening in different parts of the lenticular body, on the other.
  • optical fibres can be positioned in space without physically interfering with each other.

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  • Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • Optics & Photonics (AREA)
  • Mechanical Engineering (AREA)
  • Electromagnetism (AREA)
  • Toxicology (AREA)
  • Health & Medical Sciences (AREA)
  • General Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Laser Beam Processing (AREA)
  • Lighting Device Outwards From Vehicle And Optical Signal (AREA)
  • Non-Portable Lighting Devices Or Systems Thereof (AREA)

Claims (21)

  1. Phare de véhicule (4) comprenant
    - un corps de conteneur (8) délimité par un premier profil périmétrique (20),
    - un corps lenticulaire (24), délimité par un second profil périmétrique (28),
    - dans lequel les premier et second profil périmétrique (20, 28) du corps de conteneur (8) et du corps lenticulaire (24) sont au moins partiellement à géométries opposées l'un par rapport à l'autre de façon à s'interfacer au niveau d'une interface de soudage (32) d'un bord de butée (36) du corps lenticulaire (24),
    - ledit soudage étant un soudage de type au laser,
    - dans lequel le corps de conteneur (8) délimite un siège de retenue (12) qui héberge au moins une source de lumière et le corps lenticulaire (24) est appliqué sur le corps de conteneur (8) de façon à fermer ledit siège de retenue (12),
    dans lequel
    - le corps lenticulaire (24), au niveau dudit bord de butée (36), comprend des moyens de redirection (40) conçus pour recevoir des faisceaux laser émis par une source laser externe au phare (4) et au siège de retenue (12), pour les réfléchir en satisfaisant la condition de réflexion interne totale et pour les orienter vers ladite interface de soudage (32),
    - lesdits faisceaux laser frappant une paroi latérale externe (44) du corps lenticulaire (24), opposée au siège de retenue (12) et, après avoir traversé le corps lenticulaire (24), directement ou par au moins une réflexion, frappant lesdits moyens de redirection (40),
    - dans lequel les moyens de redirection (40) sont agencés sur une face interne (48) du corps lenticulaire (24), ladite face interne (48) faisant face au siège de retenue (12),
    caractérisé en ce que
    les moyens de redirection (40) du bord de butée (36) sont obtenus au moyen d'un évidement (84) formé sur ladite paroi latérale interne (56) du corps lenticulaire (24).
  2. Phare de véhicule (4) selon la revendication 1, dans lequel les moyens de redirection (40) sont agencés sur une face interne (48) du bord de butée (36), ladite face interne (48) faisant face au siège de retenue (12) et étant incidente avec l'interface de soudage (32).
  3. Phare de véhicule (4) selon la revendication 1 ou 2, dans lequel les moyens de redirection (40) font face au siège de retenue (12) de façon à ne pas être visibles depuis l'extérieur du phare de véhicule (4).
  4. Phare de véhicule (4) selon la revendication 1, 2 ou 3, dans lequel les moyens de redirection (40) s'étendent de manière périmétrique d'une façon continue, le long de tout le bord de butée (36) du corps lenticulaire (24), sur la face interne (48) dudit bord de butée (36).
  5. Phare de véhicule (4) selon l'une quelconque des revendications précédentes, dans lequel lesdits moyens de redirection (40) comprennent une paroi plane (52), ayant au moins un profil rectiligne par rapport à un plan de section transversale (S-S) perpendiculaire à l'interface de soudage (32) et perpendiculaire à un plan tangent à une paroi latérale interne (56) du corps lenticulaire (24), opposée à ladite paroi latérale externe (44).
  6. Phare de véhicule (4) selon la revendication 5, dans lequel ladite paroi plane (52) est inclinée de façon à identifier avec l'interface de soudage (32) un angle aigu, sur le côté opposé au siège de retenue (12), approprié pour satisfaire la condition de réflexion interne totale.
  7. Phare de véhicule (4) selon la revendication 5 ou 6, dans lequel les moyens de redirection (40) possèdent une section définie par une polyligne comprenant une pluralité de parois planes (52) munies de profils rectilignes, chaque profil droit identifiant avec l'interface de soudage (32) un angle aigu, sur le côté opposé au siège de retenue (12).
  8. Phare de véhicule (4) selon l'une quelconque des revendications 1 à 4 précédentes, dans lequel les moyens de redirection (40) comprennent une paroi curviligne (60) ayant au moins un profil hyperbolique (64), par rapport à un plan de section transversale (S-S) perpendiculaire à l'interface de soudage (32) et perpendiculaire à un plan tangent à une paroi latérale interne (56) du corps lenticulaire (24), opposée à ladite paroi latérale externe (44), dans lesquels un foyer (F) dudit profil hyperbolique (64) est positionné au voisinage de ladite interface de soudage (32).
  9. Phare de véhicule (4) selon l'une quelconque des revendications 1 à 4 précédentes, dans lequel les moyens de redirection (40) comprennent une paroi curviligne (60) ayant au moins un profil parabolique (68), par rapport à un plan de section transversale (S-S) perpendiculaire à l'interface de soudage (32) et perpendiculaire à un plan tangent à une paroi latérale interne (56) du corps lenticulaire (24), opposée à ladite paroi latérale externe (44), dans lesquels un foyer (F) dudit profil hyperbolique (68) est positionné au voisinage de ladite interface de soudage (32).
  10. Phare de véhicule (4) selon l'une quelconque des revendications 1 à 4 précédentes, dans lequel les moyens de redirection (40) comprennent une paroi curviligne (60) ayant au moins un profil curviligne (72), par rapport à un plan de section transversale (S-S) perpendiculaire à l'interface de soudage (32) et perpendiculaire à un plan tangent à une paroi latérale interne (56) du corps lenticulaire (24), opposée à ladite paroi latérale externe (44), dans lesquels un foyer (F) dudit profil hyperbolique (76) est positionné au voisinage de ladite interface de soudage (12).
  11. Phare de véhicule (4) selon l'une quelconque des revendications précédentes, dans lequel le bord de butée (36) est positionné dans une position en retrait par rapport à une paroi latérale externe (44) du corps lenticulaire (24), c'est-à-dire sur le côté du siège de retenue (12), la paroi latérale externe (44) étant opposée à une paroi latérale interne (56) du corps lenticulaire (24) qui définit au moins partiellement ledit siège de retenue (12).
  12. Procédé de fabrication d'un phare de véhicule comprenant les étapes de :
    - la fourniture d'un corps de conteneur (8) délimité par un premier profil de périmètre (20),
    - la fourniture d'un corps lenticulaire (24) délimité par un second profil périmétrique (28),
    - dans lequel les premier et second profil périmétrique (20, 28) du corps de conteneur (8) et du corps lenticulaire (24) sont au moins partiellement à géométries opposées l'un par rapport à l'autre de façon à s'interfacer au niveau d'une interface de soudage d'un bord de butée du corps lenticulaire,
    l'association, au moins partiellement l'un avec l'autre, des premier et second profils périmétriques respectifs (20, 28) du corps de conteneur (8) de façon à amener l'interface de soudage en contact avec le premier profil périmétrique,
    - la réalisation d'un soudage au moins partiel entre le corps lenticulaire (24) et le corps de conteneur (8) en correspondance avec lesdits profils périmétriques (20, 28), au travers de l'utilisation d'au moins une source laser qui émet au moins un faisceau ou rayonnement lumineux et l'orientation dudit au moins un faisceau laser sur l'interface de soudage (32) au moyen de fibres optiques (88), dans lequel le corps de conteneur (8) agit comme élément absorbant vis-à-vis du faisceau lumineux et le corps lenticulaire (24) agit comme élément transmissif du faisceau lumineux,
    caractérisé en ce qu'il
    - prévoit que le corps lenticulaire (24), au niveau dudit bord de butée (36), comprenne des moyens de redirection (40) conçus pour recevoir des faisceaux laser émis à partir d'une source laser externe au phare (4) et au siège de retenue (12), pour les réfléchir en satisfaisant la condition de réflexion interne totale et pour les orienter vers ladite interface de soudage (32), dans lequel les moyens de redirection (40) sont agencés sur une face interne (48) du corps lenticulaire (24), ladite face interne (48) faisant face au siège de retenue (12), dans lequel les moyens de redirection (40) du bord de butée (36) sont obtenus au moyen d'un évidement (84) formé sur ladite paroi latérale interne (56) du corps lenticulaire (24),
    - oriente lesdits faisceaux laser sur une paroi latérale externe (44) du corps lenticulaire (24), opposée au siège de retenue (12) de sorte que, après avoir traversé le corps lenticulaire (24) directement ou par au moins une réflexion, lesdits faisceaux laser frappent lesdits moyens de redirection (40) et sont ainsi réfléchis sur l'interface de soudage (32).
  13. Procédé selon la revendication 12, dans lequel les moyens de redirection (40) sont agencés sur une face interne (48) du bord de butée (36), ladite face interne (48) faisant face au siège de retenue (12) et étant incidente avec l'interface de soudage (32).
  14. Procédé selon la revendication 12 ou 13, dans lequel les moyens de redirection (40) font face au siège de retenue (12) de façon à ne pas être visibles depuis l'extérieur du phare de véhicule (4), et dans lequel les faisceaux laser sont émis par une source externe au phare de véhicule (4) de façon à pénétrer à travers le corps lenticulaire (24) et atteindre les moyens de redirection (40) agencés de manière interne dans le phare de véhicule (4), à savoir son siège de retenue (12).
  15. Procédé selon la revendication 12, 13 ou 14, dans lequel l'étape d'orientation des faisceaux laser sur la paroi latérale externe (44) du corps lenticulaire (24) comprend l'étape de positionnement de fibres optiques (88) à partir d'un côté de la paroi latérale externe (44) du corps lenticulaire (24) de sorte que les faisceaux laser frappent, directement ou par au moins une réflexion, les moyens de redirection (40) du corps lenticulaire (24) et, via ces derniers, frappent l'interface de soudage (32).
  16. Procédé selon l'une quelconque des revendications 12 à 15, dans lequel le procédé comprend l'étape de fourniture d'un phare de véhicule (4) selon l'une quelconque des revendications 1 à 11.
  17. Procédé selon l'une quelconque des revendications 12 à 16, comprenant l'étape de :
    - la fourniture d'au moins un dispositif collimateur (92) entre les fibres optiques (88) et le corps lenticulaire (24), de façon à collimater, le long d'un axe optique prédéterminé (X-X), les faisceaux lumineux (B) provenant des fibres optiques (88) et l'orientation appropriée sur le corps lenticulaire (24) des faisceaux lumineux (B) provenant des fibres optiques (88), de sorte que lesdits faisceaux lumineux (B) frappent, directement ou au travers d'au moins une réflexion, les moyens de redirection (40) faisant face au corps de conteneur (8) sur le côté de la paroi latérale interne (56).
  18. Procédé selon la revendication 17, dans lequel ledit dispositif collimateur (92) comprend un guide de lumière négatif (96), c'est-à-dire un guide de lumière formé de parois réfléchissantes (100) inclinées par rapport à un axe optique de la fibre optique (88), et dans lequel la fibre optique (88) est positionnée au voisinage d'une ouverture supérieure (104) du guide de lumière négatif (96) et le long de l'axe optique (X-X).
  19. Procédé selon la revendication 17, dans lequel ledit dispositif collimateur (92) comprend un guide de lumière positif (108), c'est-à-dire un corps solide approprié pour satisfaire la condition de réflexion interne totale pour l'au moins une partie de faisceau laser, le corps solide s'étendant d'une entrée (112) à une sortie (114), dans lequel l'entrée fait face auxdites fibres (88) et la sortie (114) fait face audit corps lenticulaire (24) ; dans lequel le corps solide est composé d'un matériau transparent à la longueur d'onde d'émission du faisceau laser.
  20. Procédé de fabrication d'un phare de véhicule (4) selon l'une quelconque des revendications 12 à 19 précédentes, dans lequel l'étape de soudage au laser est effectuée au moyen d'une ou de plusieurs fibres optiques (88) qui émettent simultanément des rayonnements lumineux respectifs les uns vers les autres sur différentes parties prédéterminées desdits profils périmétriques (20, 28), selon une technique de soudage « simultané ».
  21. Procédé de fabrication d'un phare de véhicule (4) selon l'une quelconque des revendications 12 à 19, dans lequel l'étape de soudage au laser est effectuée au moyen d'au moins une diode laser mobile qui est guidée de façon à orienter le rayonnement lumineux le long desdits profils périmétriques (20, 28), selon une technique de soudage « par contour ».
EP16172044.6A 2015-06-01 2016-05-30 Procédé de production d'un phare de véhicule et phare de véhicule associé Active EP3115678B1 (fr)

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CN106195694B (zh) 2020-03-13
US10781990B2 (en) 2020-09-22
EP3115678A1 (fr) 2017-01-11
US20160348866A1 (en) 2016-12-01
ES2857603T3 (es) 2021-09-29

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